Mat and method of manufacturing it



April 30, 1935. s. CLARK 1,999,441

MAT AND METHOD OF MANUFACTURING IT Filed July 18, 1932 W/ 71% W M NEN-rolaA Samuel C. 674275 atented pr.. 30, 193

man.

'r rrnon or Samuel 0. Ciarh, `Pentium Rubber (Comp, can

acre rr ltliiclr., assigner to Raida corporation ci? Iii/inchinppueatm .tary ia resa. saranno. craters ucraina i The invention relates generally to laminated ar-s ticles and it has particular relation to an automobile floor mat and method of manufacturing it.

One object of the invention is to provide a door t which is inexpensive in construction, and

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durable and eicient to an improved degree.

Another object of the invention is to provide a :door mat which is substantially waterproof while still obtaining the advantages of the conventional door mat of the fabric typ'e.

Another object of the invention is to provide a laminated door mat of vulcanized construction, which simulates the conventional fabric type of stitched floor mat.

Another object -of the invention is to provide a method of manufacturing a :door mat in an inexpensive manner to the end that floor mats of the general character set forth above may be manufactured economically and efciently.v

Other objects of the invention will be apparent lfrom the following description taken in conjunction with the drawing, wherein:

Figure l\is a, plan view of `a floor mat constructed according to one form of the invention;

Fig. 2 is a fragmentary cross-sectional view of a layer of fabric that may be employed, prior to treating the fabric with rubber;

Fig. 3 is a similar view of the fabric, after it has been treated with a latex or rubber solution;

Fig. 4 is a cross-sectional view of the fabric after a narrow strip of rubber has been disposed along the margin thereof;

Fig. 5 is a cross-sectional view of a mold illustrating the manner in which the mat as finally assembled, is vulcanized;

Fig. 6 is a cross-sectional view of the mat subsequent to vulcanization:

Fig. 'i is a cross-sectional view of a mat constructed according to another form of the invention in which a l'ayer of soft, rcushioning material is applied to the bottom or rubber side of the mat.

Referring to Figs. l and 6, the mat illustrated comprises a base layer of rubber it, and an upper layer of fabric ii bonded to the base layer by vulcanization. 0n the upper surface of the fabric ii, and around the margin thereof, a thin strip of rubber i2 is provided with is likewise bonded to the fabric by vulcanization. The inner edge of ythis strip of rubber i2 is beveled toward the fabric as indicated at it to avoid any sharp edge at this point and in general to improve the appearance of the t. Preferably along this beveled surface or adjacent thereto, the strip of rubber it during vulcanization is provided with indentations, simula a threaded se run- Cil.. 11541.@2)

ning around the margin of the mat, so that in appear-ance the strip ir seems to be sewn to the fabric. Some fabric mats have a narrow strip of closely woven fabric running'around the edge thereof this narrow strip of rubber having the imitation seam simulates a mat of the last-mentioned character. Inwardly of the margin, a rectangular layer of rubber iii is vulcanized to the upper surface of the fabric edge thereof, a bead i5 is provided to avoid a sharp edge and to improve the appearance of the mat. This layer of rubber it as best shown by rig. 1 is so located on the mat that in use, u is adapted to support the heels of the operator's M5 shoes during ordinary positioning of the meet in manipulating the foot pedals of the vehicle. s rubber naturally wili prevent excessive wear caused by the heels of the operator engaging the mat andparticularly is useful in the case of the 2@ woman driver whoV ordinarily wears high and sharp heels. j

In manufacturing a mat of this character, it is preferred to taire the fabric 'i i as shown by Fig. 2, and pass it through a latex,J solution or a 25 solution of rubber and a solvent therefor. This step in the manufacture .largely saturates and thinly coats all of the exposed fibers in the fabric with rubber and thereby renders the fabric substantiallv waterproof although to outward appear- 30* ances, no rubber is ordinarily visible. Fig. 3 has been shown to illustrate the fabric as thus treated with the latex solution or rubber solution in which a solvent is employed` After the fabric has thus been treated, the narrow strip of unvulcanized rubber i2 is disposed around the margin of the fabric and it will be 'understood that the unvulcanized condition of this narrow strip of rubber will cause it toadhere yrmly to the fabric when it is once disposed in 40 proper position. In vulcanizing the mat, va mold is employed as shown by Fig. 5, comprising a lower form il and an upper form it.l The lower form p has a recess it for accommodating the rectangular layer of rubber it, and a groove it around this 4 recess for forming the bead i5. Initially, the layer of rubber Ml may be disposed in the recess it and over the groove it and then the fabric with the narrow strip of rubber it around it may 5b be disposed on the lower form il and over the strip Mir. For vaccommodating the strip it, the lower form il is provided with a recess t@ which is tapered at its inner edge as indicatedat di to provide the beveled surfaceit preiously men sa which is sewn to the body of the mat and ii and preferably around the m tioned. The base layer of initially unvulcanized rubber I may be disposed on the back-side of the fabric prior to inserting it on the mold or after' the fabric is disposed on the lower mbold form. During vulcanization, the several parts of the mat are strongly bonded together'by vulcanizetion of the rubber, and during this operation in which pressure of course is employed, thebead I9 and lbeveled surface 2| are formed. The form l1 preferably has along the beveled surface 2i or adjacent thereto, indentations for formingA the Athread or seam simulation in the finished mat. In a mat of this character, it is apparent that the base layer of rubber l0 will firmly support and maintain the shape of the mat while still providing flexibility and that the fabric will bestrongly bonded thereto to maintain the unitary `character of the construction. The narrow strip of rubber l2 prevents fraying of the edges of the fabric and at the same time gives to the mat the appearfance of the ordinary fabric type of mat construction wherein a narrow binding strip is sewn to a fabric base. The bevel I3 and head l5 not only enhance the appearance of the mat but prevent `any sharp edges that would tend to catch on the edge of the shoes of Vany one in the vehicle.

, 1 The fabric upper layer is ordinarily desirable in a mat construction because it lends a comfortable appearance to the interior of the vehicle and also gives a soft base to the'oor thereof. Treating this fabric with latex or rubber in a solvent,

substantially renders it waterproof and enables securing a stronger bond to the base layer of rubbei;y l0, while at the sametime retaining the advantages of -the fabric mat both from the utility v and appearance points of view. Treating the fabric il with the rubber solution also is advantageous in preventing dirt and the like from becoming strongly lodged in the fabric. Furthermore, a mat of this character may be washed with water without the disadvantage of the fabric absorbing the water appreciably and the necessity of a long period for .drying out the fabric.

, In the construction shown by Fig. 7, a layer of felt 22, for example, may be secured to the lower surface of the rubber layer lo by cementing or by vulcanization. If it is vulc 2.11.: -f to the layer I0, the felt may be disposed in a mold along with thel mat shown by Fig. 6, and vul-l canized to the base layer Il, but in this case,A the felt probably wouldbe compressed to such extent that it would be desirable to subsequently revive its cushioning properties and this may be effected by throwing a jet of steam on the compressed felt, following removal of the mat from the mold, to loosen it up and render it more compressible.

Although more than one form ofthe invention has been illustrated and described in detail, it will be apparent to those skilled in the art that various modifications may be made without departing from the scope of the appended claims.

What I claim is:

l. The method of manufacturing a mat which comprises treatingV wovenfabric with a liquid rubber solution, disposing a narrow strip of rubber around a face margin of the fabric, superimposing the assembly over a niold form having a section of rubber located in a cavity therein, with the rubber strip next to the form, applying a rubber backing to the fabric, and vulcanizing the assembly under pressure.

2. The method of manufacturing a mat which comprises treating woven fabric with a liquid rubber` solution, disposing a narrow strip of rubber around the face margin of the fabric, superimposing the assembly over a mold form with the rubber strip next to the form, applying a rubber backing to the fabric and vulcanizing the assembly under pressure.

3. The method of manufacturing a mat which comprises treating woven fabric with a liquid rubber solution, applying a narrow strip of rub,-

ber around a face margin of the fabric, applythe fabric and then vulcanizing the assembly.

SAMUEL C.

ing a rubber backing over the opposite face of .'45 

